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SolidCAM + SOLIDWORKS
The Complete Integrated Manufacturing Solution
SolidCAM 2020
Milling Training Course
2.5D Milling
©1995-2020 SolidCAM
All Rights Reserved.
Contents
Contents
1. Introduction
2. CAM-Part Definition
v
6. ToolBox
vi
Introduction 1
1.1 About this Course
The goal of this course is to teach you how to use SolidCAM to machine various parts applying
2.5D Milling technologies. This course covers the basic concepts of SolidCAM 2.5D machining
and is a supplement to the system documentation and online help. Once you have developed
a good foundation in basic skills, you can refer to the online help for information on the less
frequently used options.
Course design
This course is designed around a task-based approach to training. With the guided exercises you
will learn the commands and options necessary to complete a machining task. The theoretical
explanations are embedded into these exercises to give an overview of the SolidCAM 2.5D
Milling capabilities.
Using this training book
This training book is intended to be used both in a classroom environment under the guidance
of an experienced instructor and as self-study material. It contains a number of laboratory
exercises to enable you to apply and practice the material covered by the guided exercises. The
laboratory exercises do not contain step-by-step instructions.
Training materials
The file archive supplied with this book contains copies of various files that are used throughout
this course. The Exercises folder contains the files that are required for guided and laboratory
exercises. The Built Parts folder inside the Exercises contains the final manufacturing projects
for each exercise. Unpack the complete Exercises folder on your computer. The SOLIDWORKS
files used for the exercises were prepared with SOLIDWORKS 2020.
Windows 10
The screenshots in this book were made using SolidCAM 2020 SP0 integrated with SOLIDWORKS
2020 running on Windows 10. If you are running on a different version of Windows, you may
notice differences in the appearance of the menus and windows. These differences do not affect
the performance of the software.
2
1. Introduction
3
1.2 Basic Concepts
The major stages of the SolidCAM manufacturing project creation process are the following:
CAM-Part definition
This stage includes the definition of the global parameters of the Manufacturing
Project (CAM-Part). You have to define a number of Coordinate Systems that describe
the positioning of the part on the CNC-machine.
Optionally, you can define the Stock model and Target model to be used for the rest
material calculation. The Stock model describes the initial state of the workpiece that
has to be machined. The Target model describes the one that has to be reached after
the machining. After every operation, SolidCAM calculates how much material was
actually removed from the CAM-Part and how much material remains unmachined (rest
material). The rest material information enables SolidCAM to automatically optimize
the tool path and avoid the air cutting.
Operations definition
SolidCAM enables you to define a number of milling operations. During an operation
definition you have to select the Geometry, choose the tool from the Part Tool Table
(or define a new one), define a machining strategy and a number of technological
parameters.
4
CAM-Part Definition 2
The CAM-Part definition process includes the following stages:
CAM-Part creation
CNC-controller definition
• CAM-Part creation. According to default settings, the CAM-Part name and location
are defined automatically. However, you can define them manually, if you choose
the manual option. At this stage, SolidCAM defines the necessary system files and a
folder to allocate the place to store SolidCAM data.
• CNC-controller definition. Choosing a CNC-controller is a necessary step. The
controller type influences the Coordinate System definition and the Geometry
definition.
• Coordinate system definition. You have to define the Coordinate System – the origin
for all machining operations of the CAM-Part.
• Stock model definition. SolidCAM enables you to define the stock model that
describes the initial state of the workpiece to be machined.
• Target model definition. SolidCAM enables you to define the model of the part in its
final state after the machining.
The following exercises describe the full process of the CAM-Part definition. It is recommended
to complete the stages in order to understand how the CAM-Part features are built. For this
purpose, you have to turn off the automatic CAM-Part definition.
6
2. CAM-Part Definition
Before you start, select SolidCAM Settings command from SolidCAM main ribbon.
7
In the left pane, select Defaults > Template. In the right pane, under 2.5D Milling, clear all the
check boxes next to the template names.
8
2. CAM-Part Definition
At the next stage, you have to decide on what type of CNC-machine you are going to use
9
1. Load the SOLIDWORKS model
Load the Exercise1.sldprt model located in the Exercises folder.
This model contains a number of features forming the solid body of the cover.
2. Start SolidCAM
To activate SolidCAM, click Tools in the main menu of SOLIDWORKS and then
choose SolidCAM > New > Milling.
10
2. CAM-Part Definition
SolidCAM is started, and the Milling Part Data dialog box is displayed.
11
You can define the Coordinate System origin position and axes
orientation by selecting model faces, vertices, edges, or
SOLIDWORKS Coordinate Systems. The geometry for the
machining can also be defined directly on the solid model.
Coordinate
System
Z
Y
Z
Y
X X
Y
Coordinate
Coordinate
System
System Z
12
2. CAM-Part Definition
The CoordSys dialog box enables you to define the Coordinate System location and
the orientation of the axes.
13
Normal to current view
This option enables you to define the Coordinate System with the
Z-axis normal to the model view you are facing on your screen.
The CoordSys origin will lie in the origin of the SOLIDWORKS
Coordinate System, and the Z-axis will be directed normally to the
chosen view of the model.
By 3 points (associative)
Model box
14
2. CAM-Part Definition
6. CoordSys Data
This dialog box enables you to define the machining levels such as Tool start level,
Clearance level, Part Upper level, etc.
15
This planar surface provides you the possibility to select points that
do not lie on the model entities. It is suppressed by default and not
visible until you unsuppress it in the FeatureManager Design tree.
The Planar and Rear Levels sections contain sets of facial machining
levels describing the planes parallel to the XY-plane and located along
the Z-axis.
The Levels: Planar section displays levels for milling from the positive
Z-direction.
The Levels: Radial section contains a set of machining levels
describing the virtual cylinders situated around the Z-axis.
The Levels: Rear section displays levels for milling from the negative
Z-direction. The negative Z-direction can be used in case of milling
of the part from the back side with the same Coordinate System in
the main spindle or in case of using the back spindle.
These sections contain the following parameters:
• The Tool start level defines the Z-level at which the tool starts
working.
• The Clearance level is the Z-level to which the tool moves rapidly
from one operation to another (in case the tool does not change).
• The Part Upper level defines the height of the upper surface of
the part to be milled.
• The Part Lower level defines the lower surface level of the part to
be milled.
Tool start
level
Rapid movements area
Part Upper
Clearance Feed movements area level
level Part Lower
level
• The Tool Z-level parameter defines the height to which the tool
moves before the rotation of the 4/5 axes to avoid collision
between the tool and the workpiece. This level is related to the
CoordSys position and you have to check if it is not over the limit
switch of the machine. It is highly recommended to send the tool
to the reference point or to a point related to the reference point.
16
2. CAM-Part Definition
Shiftis the distance along each axis (X, Y, Z) from the Machine
Coordinate System to the location of the Position in the coordinate
system and the orientation of the Machine Coordinate System.
Rotation is the angle of rotation around the main axes X, Y and Z.
The Plane box defines the default work plane for the operations
using this CoordSys, as it is output to the CCode program. In the
SolidCAM CAM module, you must always work on the XY-plane.
Some CNC-machines, however, have different axes definitions and
require a GCode output with rotated XY-planes.
17
This dialog box enables you to choose the mode of the Stock model definition.
Choose the Box mode from the Defined by list. The appearing
parameters enable you to select a solid body for the surrounding
box calculation.
18
2. CAM-Part Definition
Optionally, offsets from the model can be defined. In this exercise, define the stock
model offsets as follows:
• For the X+, X-, Y+ and Y- offsets, use the
values of 2
• For the Z+ offset, set the value to 0.25
• For the Z- offset, set the value to 5
Click on the solid body. One of its faces is
highlighted.
19
The Target dialog box is displayed.
Click on the solid body to choose the target. The solid body is highlighted, and the
Solid 1 icon appears in the Selection section. The target model is defined.
20
2. CAM-Part Definition
At this stage, the definition of the CAM-Part is finished. The definition of Milling
operations is covered in the following exercise using this CAM-Part.
• CAM-Part header
21
Double-click this subheader to review your machine configuration
and parameters.
The CoordSys Manager subheader is located under the CAM-
Part header. Double-click this subheader to display the CoordSys
Manager dialog box that enables you to manage your Coordinate
Systems.
The Stock and Target subheaders are located under the CAM-Part
header. Double-click these subheaders to load the Stock/Target
dialog boxes that enable you to change the definition of the
Stock/Target models.
The Updated stock subheader is located under the Target header.
Right-click this subheader to display the menu that enables you to
calculate the updated stock and rest material.
The Settings subheader is also located under the CAM-Part header.
Double-click this subheader to load the Part Settings dialog box
that enables you to edit the settings defined for the current CAM-
Part.
• Tool header
This header can recognise and process the holes created with
SOLIDWORKS Hole Wizard feature and perform machining of
the holes automatically.
• Geometries header
This header displays all SolidCAM geometries that are not used
in the operations.
• Fixtures header
22
2. CAM-Part Definition
• Setup header
23
24
SolidCAM 2.5D
Operations 3
SolidCAM offers you the following types of 2.5D Milling operations:
Profile T-Slot
Pocket Drilling
Drill Recognition
26
3. SolidCAM 2.5D Operations
Profile Operation
You can mill on or along a contour. The profile geometry can
be open or closed. In profile milling you can optionally use
tool radius compensation to the right or to the left side of the
geometry. SolidCAM offers two types of profiling:
• Milling a single profile to the specified constant or
variable depth in one step or in several user-defined
down steps.
• Concentric profiles to the specified constant or variable
depth; this type of profiling generates several concentric
profiles that start from the defined clear offset distance
from the profile, and finish on the profile geometry,
thus clearing the area around the profile to a constant
depth.
Contour 3D Operation
This operation enables you to utilize the power of the 3D
Engraving technology for the 3D contour machining. In this
operation, SolidCAM enables you to prevent the gouging
between the tool and the 3D contour.
27
Pocket Operation
In pocket milling, you have to remove material from the
interior of a closed geometry. SolidCAM offers two types of
pocketing:
• When a profile geometry consists of one or more
profiles and none of them are enclosed or intersect
with one another, each is milled as a separate pocket
without islands.
• When a profile geometry consists of several profiles,
any profile that is enclosed or intersects with another
profile is treated as an island. You can define an
unlimited number of islands within a single pocket.
Drilling Operation
This operation enables you to perform drills and other
canned drill cycles. SolidCAM supports the canned drill cycles
provided by your particular CNC-machine such as threading,
peck, ream, boring, etc. If your CNC-machine has no canned
drill cycles of its own, they can be defined using the VMID
Editor. In the Technology list, you can choose the option of
Thread milling to save and copy a drilling operation and then
change the operation to a thread mill operation
Multi-depth Drilling
Multi-depth drilling is very useful for deep hole drilling and drilling
through cross holes. In this operation, you have full control
of Drilling operations at every depth. The Multi-depth drilling
operation enables you to define manually the areas where the feed
rate changes. You can manually control the Spin rate/direction
and coolant control during the retract and engage movements.
28
3. SolidCAM 2.5D Operations
Slot Operation
This operation generates a tool path along the centerline to the
right or to the left of one or more profiles. Two types of slots can
be defined: the Slot with constant depth operation machines the
slot in several steps until the final depth is reached. In Slot with
variable depth, the depth profile is also defined by a 2D section.
The slot can be pre-machined using rough and semi-finish cycles.
The finish cut produces a tool path according to the specified
scallop height on the floor of the slot.
With available parameters for the right and left extension and the
side step, you can mill a slot wider than the tool diameter. All slot
technologies in Toolbox Cycles operations are enabled to use Pre-Drill operations.
T-Slot Operation
This operation enables you to machine slots in vertical walls
with a slot mill tool.
Translated Surface
This operation enables you to generate translated surface by
moving a section along a profile geometry. Limit geometries
can be projected on the translated surface. You can machine
the resulting translated surface inside, outside or along the limit
geometry.
ToolBox Cycles
This operation enables you to choose a machining scenario
intended for a specific machining case from a set of pre-defined
2.5D Milling operations.
29
Engraving
This operation enables you to mill text or any other profile on
a 2D or 3D geometry. Both 2D and 3D Engraving strategies
are available.
Pocket Recognition
This operation recognizes automatically pocket features at
the target model and creates the necessary machining.
Drill Recognition
This operation carries out a highly efficient drill recognition
and geometry creation with the functionality of the AFRM-
module (Automatic Feature Recognition and Machining). In
this operation drilling on different levels can be carried out.
The drilling levels are automatically recognized, but may be
edited by the user.
Chamfer Recognition
This operation recognizes automatically chamfer features at
the target model and creates the necessary machining.
30
3. SolidCAM 2.5D Operations
31
2. Add a Face Milling operation
In SolidCAM Manager, right-click the Operations header and choose Face from the
Add Milling Operation submenu.
32
3. SolidCAM 2.5D Operations
The Type section enables you to define the face milling geometry using
the following methods:
33
• Model
34
3. SolidCAM 2.5D Operations
• Profile
In the Type section, use the default Model option for the Face Milling geometry
definition. Click the Define button in Base Geometry section. The 3D Geometry
dialog box is displayed.
35
To remove selection from all objects in the list, click Unselect all.
36
3. SolidCAM 2.5D Operations
The Choosing tool for operation dialog box with the Part Tool Table is displayed.
The Part Tool Table contains all tools available for use to machine
a specific CAM-Part. The Part Tool Table is stored within the CAM-
Part. This dialog box enables you to manage the tools contained in
the Part Tool Table.
Currently, the Part Tool Table is empty. Define a new tool suitable for face milling.
Click to start the tool definition.
The available tools are displayed on the right pane.
This dialog box enables you to add a new tool to the tool library choosing from the
tools available for the current operation. In this operation, a face mill of Ø100 will
be used.
37
Face mill
This tool type is used for machining of large flat surfaces. A tool of
this type is defined with the parameters shown in the image.
Arbor Diameter
Total Length
Shoulder
Outside
Length
Holder
Length
Cutting
Length Taper
Angle
Tip Diameter
Diameter
Choose the Face mill tool. A new Face mill is added with default parameters.
On the Topology page, edit the following parameters:
• Set the Diameter to 100
• Set the Arbor diameter to 80
Click to confirm the tool parameters and choose the tool for the operation.
38
3. SolidCAM 2.5D Operations
39
6. Define the technological parameters
Switch to the Technology page of the Face Milling Operation dialog box. In the
Technology section, choose the One Pass option.
40
3. SolidCAM 2.5D Operations
The Tool path modifications section enables you to define the angle
between the tool path and the geometry,
and the shift from the central line.
Click .
The Face Milling operation data is saved, and the tool path is calculated.
The preview of the calculated tool path is
displayed on the solid model.
8. Simulate
41
The solid stock model defined in Exercise #1 is used in the SolidVerify
simulation mode. During the machining simulation process, SolidCAM
subtracts the tool movements (using solid Boolean operations) from the
solid model of the stock. The remaining machined stock is a solid model
that can be dynamically zoomed or rotated. It can also be compared to
the target model in order to show the rest material.
During the simulation, you can rotate , move , or zoom the
model. Use these options to see the machining area in details.
The Single step mode can be used to simulate the next tool movement
by clicking or by using the space bar on your keyboard.
Close the simulation with . The Face Milling Operation dialog box is displayed.
Close this dialog box with .
Click the check box next to the defined Face Milling Operation to hide the preview
of the tool path.
9. Add an operation
Right-click the Operations header in
SolidCAM Manager and choose Profile from
the Add Milling Operation submenu.
42
3. SolidCAM 2.5D Operations
The Geometry Edit dialog box is displayed. This dialog box enables you to add and
edit geometry chains.
43
When this dialog box is displayed, you can select solid model entities for the
Geometry definition.
44
3. SolidCAM 2.5D Operations
When you select the Smart Face check box, it allows you to pick
a geometry directly from the face that automatically recognizes all
open edges, holes, bosses or semi-open pockets or a completely open
pocket.
Up to Entity
With this option, the chain is selected by specifying the start curve,
the direction of the chain and the element up to which the chain is
created. SolidCAM enables you to choose any model edge, vertex or
sketch entity to determine the chain end.
End entity
45
If the chosen end item cannot be reached by the chain flow, the chain
definition is terminated when the start chain segment is reached. The
chain is automatically closed.
End entity
This option identifies only entities on the same XY-plane with the
previously selected chain entity. You are only prompted to identify
the next chain element when two entities on the same Z-level are
connected to the
chain. The system
tolerance for this
option can be set
in the SolidCAM
Settings.
46
3. SolidCAM 2.5D Operations
You are required to enter a positive and negative Z-deviation into the
Delta Z Tolerance edit boxes. Only entities within this range are
identified as the next possible entity of the chain.
Choose Yes to accept. If you answer No, you can continue the
chain selection: for example, undo the last step or cancel the
chain selection.
The combination of Constant Z and Tangent Propagation options
enables you to choose entities which continue the chain with either
tangent or having the same Z-level entities.
This option enables you to close the gaps between successive chain
entities irrespective of the Gap minimum
and Gap maximum values (defined in the
Defaults > Geometry section of SolidCAM
Settings) by virtually extending the
entities up to their intersection.
47
Splines and arcs are extended by lines tangential to the arc/spline at
its end point.
Loop
This option enables you to select a loop by picking one of the model
edges.
Loop #2
Loop #1
1. Pick an edge shared by two model faces. Two faces to which this
edge belongs are determined, and their loops are highlighted.
The first determined loop is considered to be the primary and
is highlighted with yellow color. The second loop is considered
to be the secondary and is highlighted with blue color.
2. Choose one of the loops. Click on any other edge forming
the face. You are prompted to accept the chain that is now
highlighted with yellow color. Accept the chain with the Yes
button. A closed geometry chain is defined on this loop, and
the secondary loop is rejected.
48
3. SolidCAM 2.5D Operations
• When you select a virtual line between two edges, the line
behaves as a spring. Whenever the model is changed and
synchronized, the geometry is updated with the model.
• When you select a sequence of several virtual lines, only the points
connected to model edges or sketch elements are updated, but all
other points stay fixed at the defined X-, Y- and Z-positions.
49
Arc by points
Second Third
point point
First
point
50
3. SolidCAM 2.5D Operations
When you pick the first chain entity on the solid model, SolidCAM
determines the start point of the picked entity closest to the picked
position. The direction of the picked first chain entity is defined
automatically from the start point to the picked position.
Starting point
Direction
Picked position
Geometry chain
Choose the Loop option in the Chain section and click on the model edge as shown.
Notice that the picked position must be close to the start point of the
geometry.
51
Two faces shared by the selected edge are determined, and their loops are highlighted.
The arrow indicates the direction of the selected chain.
At this stage, the Geometry is defined. Confirm the Geometry selection with .
The Profile Operation dialog box is displayed.
52
3. SolidCAM 2.5D Operations
The Part Tool Table with the tool used in the previous operation is displayed.
Click to start the tool definition.
These tool types are used for the definition of rough/finish mills.
The tool shapes and basic parameters are shown below:
53
Click the End Mill tool to choose it for the operation.
In the Tool parameters section, under Topology, set the Diameter value to 16.
Click to confirm the tool parameters and choose the tool for the operation.
54
3. SolidCAM 2.5D Operations
The Spin finish check box enables you to optionally define different
values for Spin rate and Spin finish. When this check box is selected,
the corresponding edit box is available so that you can edit its value.
When this check box is not selected, the specified Spin rate value is
used for both rough and finish machining.
The Feed finish check box enables you to optionally define different
values for Feed XY and Feed finish. When this check box is selected,
the corresponding edit box is available so that you can edit its value.
When this check box is not selected, the specified Feed XY value is
used for both rough and finish machining.
55
13. Define the Milling levels
Switch to the Levels page of the Profile Operation dialog box.
SolidCAM enables you to define the milling levels using the solid model data.
Upper level
Y
Upper
Profile depth Level
Profile
Click the Upper level button in the Milling levels area. The Pick Upper level dialog
box is displayed.
Select the model face as shown.
56
3. SolidCAM 2.5D Operations
The Upper level value (0) is determined and displayed in the Pick Upper level dialog
box. Confirm this dialog box by clicking .
Click the Profile depth button in the Milling levels area. The Pick Lower level dialog
box is displayed.
Pick the bottom edge of the model as shown. The Lower level value (-10) is
determined and displayed in the Pick
Lower level dialog box. Confirm this
dialog box with
The Delta parameter defines the offset for the cutting depth that can
be changed with its associativity preserved. The Delta value is always
relative to the Profile depth defined for the operation.
57
Modify
The Tool side option enables you to determine the tool position
relative to the geometry.
Right – the tool cuts on the right side of the profile geometry.
Left – the tool cuts on the left side of the profile geometry.
Center – the center of
the tool moves on the profile geometry (no
compensation G4x can be used with this option).
The Geometry button displays the Modify Geometry dialog box that
enables you to define the modification parameters of the geometry
and to choose which geometry chains are active in the operation (in
case of multiple chain geometry). The chain geometry of the profile
is displayed on the model with the chain direction indicated and a
circle representing the tool relative to the geometry.
In this case, the default Left option meets the requirements of climb milling. Click
the Geometry button to check the tool position.
This tool position is correct. Click to close the Modify Geometry dialog box. The
Profile Operation dialog box is displayed again.
SolidCAM enables you to perform the rough and finish machining of the profile in
a single Profile operation.
58
3. SolidCAM 2.5D Operations
Define the parameters of the Profile roughing. Select the Rough check box. Define
the Step down parameter for roughing.
Step down
Step down
Profile roughing is performed
Upper
in constant Z-passes. The Step level
down parameter defines the
distance between each two
successive Z-levels. Profile
depth
Set the Step down to 5. With this value, SolidCAM performs two cuts at the following
Z-levels: -5, -10; the last cut is performed at the Z-level defined by Profile depth.
Now you need to define the wall offset that will remain after the roughing passes.
Offsets
The Wall offset and Floor offset parameters enable you to define the
allowances that remain on the walls and the floor of the machined
part till the profile finish machining. These allowances can be removed
with the finish passes in the same Profile operation or in an additional
Profile operation with another tool.
Step down
Wall offset
Profile depth
Floor offset
In the Offsets section, set the Wall offset value to 0.5. The allowance of 0.5 mm
will be left on the model walls during the profile roughing. This allowance will be
removed with a separate finishing cut in the end of the profile machining.
Select the Finish check box to perform the finishing of the profile.
59
15. Define the Lead in and Lead out
Switch to the Link page of the Profile Operation dialog box.
This page enables you to define the way the tool approaches the profile and retreats
away.
60
3. SolidCAM 2.5D Operations
• Normal
61
• User-defined
Click . The Profile operation data is saved, and the tool path is calculated. The
preview of the calculated tool path is displayed on the solid model.
62
3. SolidCAM 2.5D Operations
Click the Simulate button in the Profile Operation dialog box. The Simulation
control panel is displayed. Switch to the Host CAD simulation mode and click .
The Host CAD simulation mode enables you to display the tool path
directly on the model in the SOLIDWORKS window. Since all the View
options of SolidCAM are active during the simulation, you can see the
tool path from different perspectives and zoom on a certain area of the
model.
Switch to the SolidVerify page and start the simulation with the .
When the simulation is finished, play the it step by step using .
Close the simulation with the . The Profile Operation dialog box is displayed.
Close the Profile Operation dialog box.
63
pocket machining. Right-click the Operations header and choose Pocket from the
Add Milling Operation submenuu.
64
3. SolidCAM 2.5D Operations
Click to confirm the tool parameters and choose the tool for the operation.
65
Define the Upper level as shown. The Upper level value (0) is determined.
Define the Pocket depth by clicking on the pocket bottom face as shown. The
Pocket depth value (8) is determined.
Set the Step down value to 4 to perform the pocket machining in two equal steps.
The default Constant depth icon indicates that the pocket will be machined at
a constant depth.
66
3. SolidCAM 2.5D Operations
When the Contour strategy is chosen, the tool moves on offsets parallel to the pocket
contour.
Switch to the Contour tab to display the Contour parameters. This page enables you
to define the parameters of the Contour strategy.
Contour parameters
Start from
• Inside
• Outside
67
• Fillet
• Sharp
68
3. SolidCAM 2.5D Operations
Direction
This option enables you to choose the method of the tool movement
within the pocket from one tool path pass to the next one.
• Smooth
• Linear
69
• Rounded
Exit material
When the tool moves from The tool exits the material
one working area to the next, and travels rapidly above the
it moves through the full material to the next working
material around the island to area as shown above. The
get to the next working area lead in path is the Lead in you
as shown above. define.
Connect islands
70
3. SolidCAM 2.5D Operations
The tool enters the material vertically at the pocket start point
chosen automatically by the SolidCAM pocket algorithm.
• Vertical
The tool moves to the pocket start point at a specified ramp angle.
Enter the ramping angle value into the Angle edit box. The start
point must be selected using the Points button.
SolidCAM does not check the ramping movement against the
pocket contour. Check the tool path simulation to make sure that
the tool does not gouge the pocket walls or islands.
• Helical
The tool descends from the safety distance above the Upper level
to the material in a circular motion until the step down is reached
using the user-defined radius. When the tool reaches the step
down depth, it machines all the material at the step down depth.
Click the Points button to set the helical ramping parameters.
• Linear
The Linear ramping follows the same rules as the Helical ramping.
The difference is that the descent is performed in a linear zigzag
fashion rather than in a circular one.
Choose the Helical option. This option enables you to define the ramping position
and the related parameters for each chain used in the Pocket operation.
71
Helical Ramping Parameters
72
3. SolidCAM 2.5D Operations
• When the tool reaches the step down depth, it machines all the
material on that step down depth.
• When the machining is completed at this depth, the tool goes up
to the Clearance level.
• At this stage, the tool repositions itself at the Z safety distance
above the previous step down depth and repeat the Helical Lead
in to the next working depth.
• This process repeats itself until the final depth has been machined.
To define the ramping position, click the Points
button. The Ramping points dialog box is
displayed.
Chains
73
When a chain entry is selected, SolidCAM displays the tool path
and the default ramping position for this chain. This position is
automatically defined at the start position of the tool path segment
relevant for the current chain. You can change this position by picking
a point on the model or by entering the new position coordinates into
the X, Y, Z dialog box. The schematic circle facilitates the definition
of the position.
When the position is picked, it is marked on the model with a blue
dot. The coordinates of the picked point are displayed in the X, Y, Z
dialog box. The circle of the tool path color represents the helical
movement of the tool plunging.
When the ramping position is defined, the tool descends into the
material at the specified ramping position with helical movements
according to the defined parameters. When it reaches the level of the
first cutting pass, it moves to the start position of the tool path and
performs machining of the pocket.
Ramping Position
The Set default button enables you to replace the currently defined
ramping position for the selected chain by the default ramping
position located at the tool path start position.
The Auto next button provides you with the selection mode that
enables you to define the ramping positions for all of the chains one
by one.
Pre-Drill Operations
74
3. SolidCAM 2.5D Operations
The following Lead in and Lead out strategies are available for pocket
machining:
• None
• Normal
Tangent
Extension Normal Length
• Arc
Tangent
Extension
Radius
75
• Tangent
Tangent
Extension Length
Under Lead in, choose the Arc option from the list and set the Tangent extension
value to 3 and the Radius value to 2.
Click . The Pocket operation data is saved, and the tool path is calculated.
76
3. SolidCAM 2.5D Operations
77
28. Define the Drill geometry
Make sure that the Technology is set to the default 2D drill
option.
In the Geometry area, click .
The Drill Geometry Selection dialog box is displayed in the SOLIDWORKS
PropertyManager area. This dialog box enables you to select the geometry for
drilling directly on the solid model.
SolidCAM enables you to select the drill centers using the following
options:
• Pick position
You can define drill centers one by one
directly on the solid model.
• 3 Points on circumference
Usually, all curves and arcs of imported
models are converted into splines by the
exporting CAD system. Due to the nature
of spline curves or surface boundaries, you
cannot pick a center position like you could
on a circle or an arc. SolidCAM calculates
the center position of an arc defined by
three points positioned on the spline edges.
This facilitates selecting drill centers on
spline surfaces.
• Multi-positions
You can select the model face. SolidCAM
automatically recognizes all arcs/circles
located on the selected face and selects the
center points as drill positions.
• All circle/arc centers
SolidCAM searches the solid model for
arcs and circles and adds all center points
as drill positions to the geometry.
78
3. SolidCAM 2.5D Operations
Choose the All circle/arc centers option and click the corresponding button.
Four drill positions are selected.
Their coordinates are displayed in
bottom part of the Drill Geometry
Selection dialog box.
Click to confirm the geometry selection. The Drilling Operation dialog box is
displayed.
Spot Drill
This tool type is used for center drilling and chamfering in Drilling
operations. A tool of this type is defined with the parameters shown
in the image.
Arbor Diameter
Diameter
Total
Outside
Length
Shoulder Holder
Length
Angle
Cutting Length
79
A Spot drill of Ø6 is used in this operation.
80
3. SolidCAM 2.5D Operations
Depth Type
This option enables you to deepen the drilled hole in order to obtain
a given diameter at the specified drill depth.
Diameter
value
• Cutter tip
The drill reaches the defined drill depth with the full diameter.
• Diameter value
The drill reaches the defined drill depth with the drill cone
diameter specified in the edit box.
The Diameter value can vary from 0 all the way up to the drill tool
diameter. A value greater than the drill tool diameter is
automatically decreased to the drill tool diameter.
Diameter_value (5)
81
In accordance with these parameters, SolidCAM calculates the centering depth using
the following formula: Diameter_value Centering_depth
Diameter_value / 2 α
Centering_depth =
tan(α/2)
Click . The Drilling operation data is saved, and the tool path is calculated.
82
3. SolidCAM 2.5D Operations
83
Define the Upper level by clicking on the top face of the model as shown.
Define the Drill depth. Rotate the model and select the bottom face as shown.
Click the Data button to define the pecking parameters. The Drill
options dialog box is displayed.
84
3. SolidCAM 2.5D Operations
Set the Step down to 1.5 in order to define the depth of each pecking movement.
Click . The Drilling operation data is saved, and the tool path is calculated.
Since in the previous operation the drilling diameter was greater than
that in this operation, the drilling results in a chamfer on the drilled
holes.
85
Exercise #3: Cover Machining
In this exercise, a number of SolidCAM 2.5D operations are used for the cover part machining.
The cover is machined on the 3-Axis milling CNC-machine using the machining vice. The part
is machined using two setups.
At the first stage, the workpiece is positioned in the vice as shown below.
86
3. SolidCAM 2.5D Operations
At the next stage, the rest of the cover faces are machined using the second positioning.
87
1. Load the SOLIDWORKS model
Load the Exercise3.sldprt model that is located in the Exercises folder.
This model contains a number of features forming the solid body of the cover.
2. Start SolidCAM
To activate SolidCAM, click Tools in the main menu of SOLIDWORKS and then
choose SolidCAM > New > Milling.
SolidCAM is started, and the Milling Part Data dialog box is displayed.
88
3. SolidCAM 2.5D Operations
Click the Add box to CAD model button. The stock model box is added into the
CAM component of the CAM-Part assembly as a 3D Sketch feature.
Confirm the Stock dialog box with . The Milling Part Data dialog box is displayed.
89
5. Define the Coordinate System
Click the CoordSys button in the Define area to start the Coordinate System
definition.
The CoordSys dialog box is displayed.
In the Definition options list, choose the Define option.
90
3. SolidCAM 2.5D Operations
This mode enables you to define the Coordinate System by picking three points on
the solid model. At first, you have to define the Coordinate System origin location
and then the points for the X- and Y-directions.
Pick the origin point in the stock box corner as shown.
Click on the stock model edge as shown to define the X-axis of the Coordinate
System.
Click on the stock model edge as shown to define the Y-axis of the Coordinate
System.
91
When a point is selected, the next button is automatically activated. If
you miss the selection, you can at any time select the button you want to
define and continue automatically to the next button.
Confirm the Coordinate System definition with . The model is rotated,
and the Coordinate System is displayed.
The CoordSys Data dialog box is displayed.
Define the Part Lower level directly on the solid model. This
parameter defines the lower surface level of the part to be
milled.
In the Levels: Planar section, click the Part Lower level
button.
Rotate the model and select the lower face that is milled using
the first positioning as shown.
92
3. SolidCAM 2.5D Operations
Confirm the CoordSys Manager dialog box with . The Milling Part Data dialog
box is displayed again.
93
Upper face machining
Then the part has to be rotated and clamped again. With the second Setup, the
following operations are performed:
94
3. SolidCAM 2.5D Operations
Pocket machining
Slot machining
Holes machining
In SolidCAM Manager, right-click the Operations header and choose Face from the
Add Milling Operation submenu. The Face Milling operation is used for the upper
face machining.
The Face Milling Operation dialog box is displayed.
95
9. Define the Face Milling geometry
96
3. SolidCAM 2.5D Operations
SolidCAM enables you to define a variety of tool holders to help you check and
prevent all possible collisions between the tool holding system and the workpiece.
This feature also enables you to see a more realistic simulation in the SolidVerify
simulation.
Switch to the Holder page in the Choosing tool for operation dialog box.
Tool adaptor
97
SolidCAM enables you to define the Tool adaptor in the *.vmid file
under Machine Definition > Devices > Spindle > Stations.
In the Global table, choose the BT40 ER32×60 collet chuck by clicking its check box.
This collet chuck is suitable for the chosen tool diameter (40 mm).
Choose the defined tool for the operation by clicking . The Face Milling
Operation dialog box is displayed.
98
3. SolidCAM 2.5D Operations
99
• Hatch angle
hatching angle.
Optimal direction
Angle
100
3. SolidCAM 2.5D Operations
• Cutting direction
The One Way option enables you to create the tool path with only
one-directional movements.
The Zigzag option enables you to create the tool path with
bidirectional movements.
• Cutting order
The Side to side option creates a tool path that starts the cutting
on one side of the geometry, machines the face according to the
Cutting direction and then performs its last cutting pass on the
side opposite of the starting side.
The Side to middle option creates a tool path that starts the
cutting on one side of the face geometry and then moves to the
opposite side before making the next cut. Each successive series
of opposing parallel passes step inward until the last cutting pass
is performed in the middle.
• Extension
During face milling, the tool path is extended over the edges of
the machined face. The Extension section enables you to define
the extension both along the tool path (the Along section) and
across the tool path (the Across section).
The extension can be defined either by percentage of the tool
diameter (the % of tool diameter option) or by value (the Value
option).
Extension across
the tool path
Extension along
the tool path
101
• Corner
Overlap
This section enables you to define the tool overlapping between two
successive passes. This option can be defined as Percentage of the
tool diameter or as a Value.
0.5D 0.2D
Overlap 0.5D Overlap 0.2D
102
3. SolidCAM 2.5D Operations
Define the roughing offset that remains on the floor of the face. This offset is left
unmachined during the rough face machining and removed during the face finishing.
In the Offsets section, set the Floor offset value to
0.2. Make sure that the Finish check box is selected to
perform finishing of the face in this operation. This
option enables you to remove the remaining offset
with the last cutting pass.
103
In the Lead out section, select the Same as Lead in check box.
Click . The Face Milling operation data is saved, and the tool path is calculated.
15. Simulate
Click the Simulate button in the Face Milling Operation dialog box. The Simulation
control panel is displayed.
Switch to the SolidVerify page and start the simulation with .
Close the simulation with . The Face Milling Operation dialog box is displayed.
Close this dialog box with .
104
3. SolidCAM 2.5D Operations
105
18. Define the Tool
Add a new End mill tool of Ø16 for the operation.
Choose the tool holder. Switch to the Holder page and click the Local holders tab.
The Local holders table contains the tool holders that were already
used in the current CAM-Part. When a new holder is chosen from
the Global holders table, it is copied to the local table to make a
further use easier.
106
3. SolidCAM 2.5D Operations
Now you have to define the roughing and finishing parameters. SolidCAM Profile
operation enables you to perform the rough and finish machining in the single
operation.
107
Select the Clear offset check box. Set the Offset value to 5 and the Step over value
to 2.5.
Clear Offset
The Step over parameter defines the overlap of adjacent tool paths.
It determines the offset between two successive concentric profiles.
Geometry
Wall offset
Clear offset
Step over
108
3. SolidCAM 2.5D Operations
Click . The Profile operation data is saved, and the tool path is calculated.
23. Simulate
Click the Simulate button in the Profile Operation dialog box. The Simulation
control panel is displayed.
Switch to the SolidVerify page and start the simulation with .
109
Click on the toolbar. The Measure Distance dialog box is displayed.
Click on the top face of the cover and then on the
horizontal face machined in the current operation.
The coordinates of the pocket points and the result distance are displayed in the
Measure Distance dialog box.
110
3. SolidCAM 2.5D Operations
In the Chain section, choose the Constant Z Propagation option. The closed chain
is automatically selected.
The confirmation message is displayed.
Confirm it by clicking Yes.
111
26. Define the Tool
In this operation, use the
same tool as in the previous
operation (Ø16 End mill).
Click the Select button in the
Tool page. The Part Tool Table
is displayed. Choose the
previously defined Tool #2 and
click .
112
3. SolidCAM 2.5D Operations
Click . The Profile operation data is saved, and the tool path is calculated.
113
31. Simulate
Click the Simulate button in the Profile
Operation dialog box. The Simulation control
panel is displayed.
Switch to the SolidVerify page and start the
simulation with .
Close the simulation with . The Profile
Operation dialog box is displayed. Close the
Profile Operation dialog box with
114
3. SolidCAM 2.5D Operations
In the same manner, define the geometry for the rest of the pads. Make sure that all
the selected chains have the same direction. Confirm the geometry definition by
clicking
115
In the same manner as explained earlier, define the Profile depth by clicking on the
pad face as shownn.
116
3. SolidCAM 2.5D Operations
39. Simulate
Click the Simulate button in the Profile Operation dialog box. The Simulation
control panel is displayed.
Switch to the SolidVerify page and start
the simulation with
Close the simulation with . The
Profile Operation dialog box is
displayed.
Close the Profile Operation dialog box
with
At this point, the machining of the external cover
faces is finished. At the next stages you have to
machine the internal faces.
117
Click the Add button. The CoordSys dialog box is displayedd.
In the Mac CoordSys number field, set the value to 2. Changing
of the Mac CoordSys number means that a new clamping is
used.
Make sure that the default Select face mode is chosen.
When this mode is chosen, SolidCAM enables you to define
a new Coordinate System by selecting a planar face. In this
case, the Z-axis of the Coordinate System is normal to the
selected face.
The Coordinate System origin is placed according to the Place
CoordSys origin to setting. Make sure that the Top corner of
model box option is chosen.
Rotate the model and click on its bottom face as shown below.
118
3. SolidCAM 2.5D Operations
The upper plane of the model box is parallel to the XY-plane of the
defined CoordSys. The CoordSys is located in the corner of the
model box with the following coordinates: (XMIN, YMIN, ZMAX).
Now you have to move the origin of the Coordinate System from the automatically
defined position to the corner of the workpiece.
Select the Pick origin check box in the Modify by pick section of the CoordSys
dialog box.
Click on the corner of the workpiece (stock model) as shown to choose it for the
origin. The origin is moved to the new location.
Confirm the CoordSys dialog
box by clicking .
119
The CoordSys Manager dialog box is displayedd.
120
3. SolidCAM 2.5D Operations
In the Type section, use the default Model option for the Face Milling geometry
definition. Click the Define button. The 3D Geometry dialog box is displayed.
Click on the solid model to select it. The model is highlighted, and its icon appears
in the list. Confirm the 3D Geometry dialog box by clicking . The Face Milling
Geometry dialog box is displayed again.
Click to confirm the Face Milling Geometry dialog box. The geometry is defined
for the operation.
121
44. Define the Milling levels
In this operation, the machining starts on the top face of the workpiece (Z=0 of the
Machine Coordinate System #2) and ends on the back face of the cover part (Z=-5
of the Machine Coordinate System #2).
Define the Upper level by clicking on the workpiece
corner as shown.
Define the Face depth directly on the solid model by
clicking on its bottom face as shown beloww.
Define the roughing offset that remains on the floor of the face. This offset is being
left unmachined during the rough face machining and is removed during the face
finishing.
In the Offsets section, set the Floor offset value
to 0.2. Select the Finish check box to perform
finishing of the face in this operation. This
check box enables you to remove the remaining
offset with the last cutting pass.
122
3. SolidCAM 2.5D Operations
In the Lead out section, select the Same as Lead in check box.
Click .
SolidCAM notifies you that the upper level chosen for the operation is above the
CoordSys Upper level.
Confirm this message with the Yes button. The operation data is saved, and the tool
path is calculated.
48. Simulate
Simulate the operation in the SolidVerify
mode.
The bottom face machining is finished. Now you have to perform the pocket
machining.
123
Pocket machining overview
124
3. SolidCAM 2.5D Operations
125
SolidCAM uses the constant-Z passes for the Pocket generation. The Step down
parameter enables you to define the distance between each two successive Z-levels.
Set the Step down value to 2. The pocket is machined in two Z-levels.
Radius
126
3. SolidCAM 2.5D Operations
57. Simulate
Perform the simulation of the Pocket
operation in the SolidVerify mode.
During the simulation, notice the
helical lead in movement.
127
61. Define the Milling levelss
The machining in this operation starts
at the Z-level of the top faces of the
pads and ends on the bottom face of
the pocket.
Define the Upper level by selecting the
top face of the pads as shown.
Define the Lower level by selecting the
bottom face of the pocket.
128
3. SolidCAM 2.5D Operations
66. Simulate
129
Make a note that the pocket geometry is not completely machined because the tool is too large to
reach some model areas. In order to complete the machining, you have to perform an additional
Pocket operation with a tool of a smaller diameter in the areas that were not machined in the
current Pocket operation.
Click to define a new tool. Choose the End mill tool from the Milling tools
table.
A new Tool #4 is added with the default parameters.
Choose the tool holder. In the Holder page, click the Local tab. Choose the BT40
130
3. SolidCAM 2.5D Operations
In the Part Tool Table, click to choose the defined tool (Ø6 End mill) for the
operation.
During the machining, when a large tool is used, the tool leaves
material in areas that it cannot enter.
Unmachined area Machined area
Geometry
The Rest material option enables you to remove the material from
these areas without defining a new geometry.
131
The new Rest tab appears and opens the page automatically.
Notice that the Separate areas option is chosen by default in the Milling type box.
When this option is chosen, SolidCAM performs the machining only in areas that
were not machined with the previous tool.
Define the diameter of the end mill that was used in the previous operation. Click
the Previous tool diameter button. The Part Tool Table is displayed with all the tools
used in the operations of the current CAM-Part. Choose the Ø16 End mill used in
the previous operation and click the Select button.
In the Previous wall offset field, set the value
of 0.2. This offset was defined in the previous
Pocket operation.
Define the Extension/Overlap parameter – the
overlap distance that you would like to start
from and end with the previous larger end mill.
Set the Extension/Overlap value to 1.
Click . The Pocket operation data is saved, and the tool path is calculated.
71. Simulate
Play the simulation of the Pocket
operation in the SolidVerify mode.
Notice that the machining is performed
only in the areas that were not machined
in the previous operation.
132
3. SolidCAM 2.5D Operations
133
76. Define the technological parameters
In this operation, use the Equal step down option to keep an equal distance between
all Z-levels.
134
3. SolidCAM 2.5D Operations
For each turn around the geometry, the tool moves downward along
the Z-axis according to the step down value. When the Profile depth
is reached by the spiral movements, SolidCAM performs the last cut
with the constant-Z movement at the Profile depth.
Step Down
Click . The Profile operation data is saved, and the tool path is calculated.
79. Simulate
Play the simulation in the SolidVerify mode.
135
80. Add a Profile operation
Add a new Profile operation to machine the walls of the islands.
Make sure that the chain direction is clockwise. Such direction enables you to
perform the climb milling of the profile.
136
3. SolidCAM 2.5D Operations
In the Chain section, choose the Constant Z Propagation option. The chain is
automatically completed.
The confirmation message is displayed. Confirm it by clicking Yes. The first chain is
defined.
Select the edge of the other island as shown below.
Make sure that the chain direction is clockwise. Such direction enables you to
perform the climb milling of the profile.
In the Chain section, choose the Constant Z Propagation option. The chain is
automatically completed and the confirmation message is displayed. Confirm it by
clicking the Yes button.
The first selected entity in the geometry chain defines the approach
location for the whole chain. In this case, the internal edges of the
pads are chosen in order to prevent the collision between the tool
and pocket wall during the lead in movement.
Confirm the Geometry definition with .
137
83. Define the Milling levelss
Define the operation Upper level
directly on the solid model by clicking
on the top face of the pad as shown.
Define the Profile depth by clicking on
the bottom face of the pocket.
87. Simulate
Play the simulation in the SolidVerify mode.
138
3. SolidCAM 2.5D Operations
139
Click on the surfaces of both tow pads and confirm your selection by clicking .
The Face Milling Geometry dialog box is displayed again. In order to machine these
two faces separately, click the Separate button in the Chain List section.
Two separate chains are created.
140
3. SolidCAM 2.5D Operations
94. Simulate
Play the simulation in the SolidVerify mode.
141
97. Define the tool
Choose the Tool #4 (Ø6 End mill) for the operation.
Click . The Profile operation data is saved and the tool path is calculated.
101. Simulate
Play the simulation in the SolidVerify mode.
142
3. SolidCAM 2.5D Operations
In SolidCAM Manager, right-click the Operations header and choose the Slot item
from the Add Milling Operation submenu.
The Slot Operation dialog box is displayed.
Make sure that the chain direction is clockwise to perform the climb milling.
143
Choose the BT40 ER16x70 collet chuck from the Global holders table for the
operation.
Click . The Slot operation data is saved, and the tool path is calculated.
144
3. SolidCAM 2.5D Operations
107. Simulate
Play the simulation in the SolidVerify
mode.
At the final stage of the cover part, you have to perform several operations to machine the holes
located on the bottom face and pads.
All the circular edges located on the selected face are collected, and the drill positions
are determined. Confirm the geometry selection with .
145
110. Define the Tool
In the Tool page, click the Select button. The Part Tool Table is displayed.
In the drilling operations of this exercise, the tools imported from an external tool
library are used. The Exercise3_Drill_Tools library contains several drilling tools
required for this exercise. This library is located in the Exercises folder you have
copied to your hard drive.
In the Part Tool Table, click to import the tool from the previously defined
tool library.
The Import from tool table dialog box is displayed. Click and choose the
location of the Exercise3_Drill_Tools tool library. Set it in the Library list.
146
3. SolidCAM 2.5D Operations
Click . The Drilling operation data is saved, and the tool path is calculated.
113. Simulate
Play the simulation of the center drilling
in the SolidVerify mode.
147
114. Add a Drilling operation
In SolidCAM Manager, add a new Drilling operation to drill the holes center-drilled
at the previous stage.
Choose the same Drill geometry used in the previous operation.
Choose the Tool #7 (Ø5 Drill) from the Part Tool Table.
Click . The Drilling operation data is saved, and the tool path is calculated.
117. Simulate
Play the simulation of the drilling in the
SolidVerify mode.
At the next stage, you have to perform a number of drilling operations (center drilling, drilling,
tapping) for eight holes located on the pads top faces.
148
3. SolidCAM 2.5D Operations
Click . The Drilling operation data is saved, and the tool path is calculated.
149
124. Define the Milling levels
In the Levels page, define the Upper level in the same manner as explained in Step
#121.
Define the Drill depth directly on the solid model. Pick the lower vertex of the hole
cone as shown to define the depth.
Click . The operation data is saved, and the tool path is calculated.
150
3. SolidCAM 2.5D Operations
In the Geometry area, choose the drill1 geometry defined in Step #119.
Choose the Tool #9 (Ø2 Tap) for the operation.
Tap Tool
Arbor Diameter
Total
Length
Outside
Holder
Length Chamfer Cutting
Length Length
Tip Diameter
Diameter
151
128. Define the Drilling depth
In the Levels page, define the Upper level in the same manner as explained in Step
#121.
Click . The Drilling operation data is saved, and the tool path is calculated.
Simulate
At this stage, programming of the machining operations is completed. Now you have to generate
the GCode to send it to the CNC-machine controller.
152
3. SolidCAM 2.5D Operations
Alternatively, you can choose GCode icon from the SolidCAM Operations toolbar.
The GCode is generated for the complete CAM-Part. The generated GCode is
displayed in the Notepad window.
153
Exercise #4: Bracket Machining
154
3. SolidCAM 2.5D Operations
155
Exercise #5: Electronic Box Machining
Define a Face Milling operation to machine the top face of the electronic box part
with the Hatch strategy.
156
3. SolidCAM 2.5D Operations
157
During the wall finish machining, use the Rest Material strategy to remove the bulk
of material in the corners.
158
3. SolidCAM 2.5D Operations
159
Exercise #6: Clamp Machining
Define the CAM-Part and operations for the machining of the clamp part presented on the
illustration on a Milling CNC-machine.
160
3. SolidCAM 2.5D Operations
2. Holes machining
Perform a number of Drilling operations to
machine the holes.
Use the appropriate Machine Coordinate
System defined for the positioning shown
below.
161
Add a new Pocket operation. In this operation, the open pocket machining strategy
will be used.
Select the open pocket geometry chain as shown.
Click to confirm the selected chain. The Close Chain dialog box is displayed.
162
3. SolidCAM 2.5D Operations
Select the Mark line as open edge check box and confirm the dialog box with OK.
The open edge is marked.
Confirm the Geometry Edit dialog box by
clicking .
Choose the Ø6 End mill for the operation.
Select the upper face of the model as the Upper
level and the pocket floor as the Pocket depth.
Extension
This section enables you to define the overlapping between the tool
and the open edges. The overlapping can be defined as percentage of
the tool diameter (the % of tool diameter option) or as a value (the
Value option).
Open edge
Extension
163
Set the Extension value to 60% of the tool diameter. Since the diameter of the tool
used in this operation is 6 mm, the tool path is extended by 3.6 mm over the open
pocket edge.
Note that the Extension value cannot be smaller than the radius of the
tool.
164
3. SolidCAM 2.5D Operations
This option enables the tool to approach from outside of the material
in the open pocket areas, if possible. Such approach enables you to
decrease the tool loading when plunging into the material. This
option enables you to perform the approach movement from the
automatically calculated point outside of the material. The tool
moves to the required depth outside of the material and then plunges
into the material.
Switch back to the Technology tab. In the Offsets section, set the Wall offset and the
Floor offset to 0.2. To remove these offsets with the finishing cut, select the Wall and
Floor check boxes in the Finish section.
4. Hole machining
Define two Drilling operations to perform
center drilling and drilling of the hole located
at the bottom of the open pocket. Use the
same Machine Coordinate System (positioning)
as in the previous operation.
165
5. Step machining
Define a Profile operation to machine the step.
Define the Machine Coordinate System for the
positioning shown below.
Use the Point to point option in the Geometry Edit dialog box to define the geometry.
This option enables you to connect the specified points. The points
are connected by a straight line. This option is useful when it is
impossible to define the geometry using the model edges.
In this exercise, it is impossible to define the straight geometry for
the Profile Milling using the model edges. The Point to point option
enables you to define the geometry by two points located on the
model vertices.
166
3. SolidCAM 2.5D Operations
Use the Zigzag method for Depth cutting type to connect the successive Z-level
passes directly from the end of a pass to the beginning of the next pass.
167
Exercise #7: Basic Part Machining
168
3. SolidCAM 2.5D Operations
3. Step machining
Perform the rough and finish machining of the
step faces using the Profile operation.
169
7. Connector opening finish machining
Use the Pocket rest material strategy to perform
the finish machining of the connector opening
faces.
170
3. SolidCAM 2.5D Operations
171
Exercise #8: Cover Machining
Default Stock
The following steps have to be implemented in order to reach the final CAM-Part:
172
3. SolidCAM 2.5D Operations
Profile Machining
Profile 3D Machining
173
4. Define the Tool
Add a new Ø10 End mill tool for the operation.
In the Offsets section, set the Wall offset value to 0.2. The allowance of 0.2 mm will
be left on the hole wall during the roughing. This allowance will be removed with
a separate finishing cut in the end of the machining.
Select the Rough check box. Set the Step down to 2. The hole will be machined in
three equidistant rough passes.
Select the Finish check box. Set the Step down to 6. The finishing will be performed
in a single pass.
174
3. SolidCAM 2.5D Operations
175
10. Define the Tool
Add a new Ø10 Spot drill tool for the operation.
176
3. SolidCAM 2.5D Operations
177
Exercise #9: Mounting Base Machining
2. Contour machining
Define a Profile operation to machine the mounting
base external faces.
178
3. SolidCAM 2.5D Operations
4. Pocket machining
Define a Pocket operation to perform rough
and finish machining of the pocket faces.
Switch to the Advanced tab and click the Wall draft angle button.
179
Wall Draft Angle
This parameter defines the draft angle of the wall measured from
the Z-axis direction as shown.
For the inclined wall machining, each cutting pass located at a
specific Z-level is generated according to the specified External
wall angle value.
This option enables you to define how the cutting passes are
connected during the external corners machining. There are three
ways to connect between the cutting passes:
180
3. SolidCAM 2.5D Operations
In the new dialog box, check the Wall draft angle option.
181
Set the External wall angle to 8.
In the Cut from area, select the Bottom to top
option.
6. T-Slot machining
In SolidCAM Manager, right-
click the Operations header and
choose T-Slot Operation from
the Add Milling Operation
submenu.
The T-Slot Operation dialog box
is displayed.
Define two geometry chains as shown. Make sure the direction of the chains
geometry is the same as on the illustration.
182
3. SolidCAM 2.5D Operations
Slot Mill
This type of tool can be used for all types of machining from simple
2.5D undercuts up to 5-axis simultaneous machining.
A tool of this type is defined with the parameters shown in the image.
Arbor
Diameter
Total
Length Outside
Holder
Cutting
Corner Radius Length
Diameter
The Top tool offset number defines the register number of the upper
cutting edge of the T-slot mill. This option enables SolidCAM to
automatically take into account the minor size differences between
the defined tool and the one actually used for cutting the workpiece,
if there are any.
183
7. Define the Milling levels
Define the Ceiling (Upper level) for slot
machining by clicking on the model
face as shown.
Confirm the value (-4.5) in the Pick
Upper level dialog box.
The Wall offset option defines the offset that remains on the slot wall
after roughing.
Wall Offset
184
3. SolidCAM 2.5D Operations
The Ceiling offset option defines the offset that remains on the slot
ceiling after roughing.
Ceiling
Offset
The Floor offset option defines the offset that remains on the slot
floor after roughing.
Floor
Offset
185
Cutting depth overlap
This parameter defines the overlap of each two adjacent tool paths in
both rough and finish machining of the slot.
Cutting depth
overlap Cutting depth
overlap
186
3. SolidCAM 2.5D Operations
The following steps have to be implemented in order to perform the internal and external
threading:
187
4. Define the Tool
Switch to the Tool page of the Thread Milling Operation dialog box and click the
Select button.
Thread Mill
Outside
Holder Total
Length Length
Shoulder
Length
Thread
Cutting
Cutting Diameter Length
188
3. SolidCAM 2.5D Operations
Select the M64 x 4.0 standard from the list and click OK.
You can edit its appearance by adding a shaped tool to the Tool Library.
189
Click to save the operation without calculation. Click to exit.
190
3. SolidCAM 2.5D Operations
191
Now you have to add the tool shaft. In the same manner as described above, add
two cylinders with the following parameters:
• For Cylinder1, set the Diameter to 12 and the Height to 50
• For Cylinder2, set the Diameter to 16
and the Height to 30
The final tool shape is as shown on the picture.
Switch to the Show tab to display a 3D model of
the tool.
192
3. SolidCAM 2.5D Operations
193
10. Simulate the operatiion
Perform the simulation of the operation
in the Host CAD mode. Set the CAM-
Part in the Top view to observe that the
tool approaches the material not in the
center.
Perform the simulation of the operation
in the SolidVerify mode.
194
3. SolidCAM 2.5D Operations
195
17. Simulate the operation
Perform the simulation of the operation in the SolidVerify mode.
196
3. SolidCAM 2.5D Operations
Click . The Threading operation data is saved, and the tool path is calculated.
197
25. Simulate the operation
Perform the simulation of the operation
in the SolidVerify mode.
198
3. SolidCAM 2.5D Operations
199
3. Define the Geometry
The geometry for this operation is a set of closed chains comprising the letters.
Click in the Geometry page. In the Geometry Edit dialog box, ensure that 104
is selected from the Configurations list. Click the Add button in the Multi-chain
section. The Chains Selection dialog box is displayed.
In the Type section, choose the Faces option. All
chains found on the selected face will be added to
the geometry. To exclude from the geometry the
external chain formed by the face edges, apply a filter.
Choose the Loops filter option, and it will expand the
entire section. Clear the check box near the External
loops option. Now only letters will be included in the
geometry.
Click on the face that contains the letter. The face is
highlighted.
Click to choose the selected chains as the
geometry. The Geometry Edit dialog box is displayed.
Zoom in the selected face. Some letters consist of
two chains, internal and external, and the internal
chains are not selected automatically.
200
3. SolidCAM 2.5D Operations
In the Geometry Edit dialog box, select the Constant Z Propagation option from the
Chain section. Click on the internal chain of the letter “o”.
Accept closing the open chain. The internal chain is added
to the geometry.
Select again the Constant Z Propagation option from the
Chain section. Click on the internal chain of the letter “d”.
Accept closing the open chain. Repeat the same steps with
all letters that include internal chains: “o,” “d,” “A,” “D,”
and “R.”
Confirm the geometry definition with .
Engraving tool
This tool type is used for engraving. A tool of this type is defined
with the parameters shown in the image.
Arbor Diameter
Total
Length
Diameter Outside
Holder
Shoulder Length
Length
Cutting
Length Angle
201
Edit the following tool parameters:
• Set the Tip diameter to 0.1
• Set the Taper angle to 15
202
3. SolidCAM 2.5D Operations
Fill area
Hatch
When this option is chosen, the tool moves inside the closed
contour in linear movements.
Contour
When this option is chosen, the tool moves along the center line
of the closed contour. Selecting the V-Carving check box, creates
a 3D tool path from 2D fonts.
Click . The Engraving operation data is saved, and the tool path is calculated.
203
8. Simulate the operation
Perform the simulation of the operation in the SolidVerify mode.
Click in the Geometry page. In the Geometry Edit dialog box, click the Add
button in the Text section.
In the Text definition dialog box, click the Edit button in the
Text definition section. The Draw Tools dialog box is displayed.
Click the text symbol and draw a rectangle to define a
text frame.
204
3. SolidCAM 2.5D Operations
Type in the text that you want to engrave, for example “SolidCAM 2020.” Use the
toolbar icons to change the text properties: font, size, alignment, and so on.
Click to confirm the text.
In the Reference point section, click the Pick point button. Select the reference point
directly on the model, clicking the point in the beginning of the sketch line.
Click the Resume button in the SolidCAM dialog box.
Click Resume and accept the chains by clicking . The Geometry Edit dialog box
is displayed.
205
The Chain List section contains the Text item which
includes all selected chains. This item can be edited and
modified every time you need to make a change.
Click to choose the selected geometry for the
operation.
Click . The Engraving operation data is saved, and the tool path is calculated.
206
Indexial 4-Axis
Milling 4
SolidCAM enables you to perform indexial 4-axis milling on vertical or horizontal CNC-
machines with a 4th axis rotary table.
The 4th axis rotation is used for the positioning of the part. When the part is positioned to
the required orientation, the 4th axis is locked and the machining is performed using 3-axis
movements.
For each clamping, SolidCAM enables you to define the Machine Coordinate System with X-axis
(for vertical machines) or Y-axis (for horizontal machines) parallel to the revolution axis of the
rotary table.
Machine
Machine Coordinate Y
Coordinate System
X
Z System
Y Z
208
4. Indexial 4-Axis Milling
Within one clamping (Machine Coordinate System), SolidCAM enables you to define a number
of positions around the revolution axis. For vertical machines the X-axis of these positions is
parallel to the X-axis of the Machine Coordinate System.
Machine Coordinate System
Z
Y
Positions
Z Z
Y Y
Z Y
X X
X
For horizontal machines, the Y-axis of these positions is parallel to the Y-axis of the Machine
Coordinate System.
Machine Coordinate System
Y
X Z
Positions
Y Y
Y
X Z X Z
X Z
209
For each position, SolidCAM automatically determines the Shift and the Rotation parameters
relative to the Machine Coordinate System.
Machine
Coordinate Rotation X
System
Z Y'
Z Y Z' Y
Y'
X Position
Z' X'
Shift Z
Shift X X
Shift Y X'
The Shift components (Shift X, Shift Y and Shift Z) describe the shifting of the position relative
to the Machine Coordinate System.
The Rotation components (Rotation around X, Rotation around Y and Rotation around Z)
describe the axis orientation of the position relative to the Machine Coordinate System.
Positions can be defined only around the revolution axis. For vertical machines only positions
around X-axis can be added, so the Rotation around Y and Rotation around Z values are 0. The
Rotation around X parameter can be different from 0. For horizontal machines only positions
around Y-axis can be added, so the Rotation around X and Rotation around Z values are 0. The
Rotation around Y parameter can be different from 0.
Machine Coordinate Systems and their positions are used for the geometry definition. Before
the geometry definition you have to choose the Coordinate System position. The geometry has
to be located in the plane parallel to the XY-plane of the chosen CoordSys.
210
4. Indexial 4-Axis Milling
In this exercise, indexial 4-axis operations are used for the frame part machining.
The frame is machined from the pre-machined stock on a vertical 4-axis milling CNC-machine
using a special jig.
The jig with the clamped workpiece is placed on the rotary table of the machine. Such clamping
enables you to machine four sides of the model using the rotation of the 4th axis.
211
1. Load the SOLIDWORKS model
Load the Exercise12.sldprt model located in the Exercises folder.
The model contains three configurations:
• Default
The original design model without changes.
• Stock
The stock model that is used for the SolidCAM stock definition.
• Machining
The machining model with a tail that was not removed. This configuration
is used for the SolidCAM geometries definition.
212
4. Indexial 4-Axis Milling
Make sure that the default Select face option is chosen. Select
the Top corner of model box option in the Place CoordSys
origin to list.
213
The Machine Coordinate System #1 is automatically defined in the top corner of the
model box. Click .
The CoordSys Data dialog box is displayed.
SolidCAM automatically determines the Shift and Rotation
values. For the first Position related to a new Machine
Coordinate System, the Shift and Rotation parameters values
are always 0.
214
4. Indexial 4-Axis Milling
The origin is automatically placed in the top corner of the model. The Z-axis is
directed outwards normally to the selected face. The X-axis direction is the same as
the direction of the X-axis of the Machine Coordinate System (Position #1).
Click to confirm the position location. The CoordSys Data dialog box is
displayed.
The Part Upper level (0) and the Part Lower level (-100) are
automatically determined on the model.
The Shift and Rotation parameters are defined automatically
for the Position #2. The Shift Z is -35; the Shift X and Shift Y
are 0. The Rotation around X is -90; other Rotation values are
0.
Machine Coordinate System
Z Position #1
Rotation X X
-90° Y
Shift Z
35 Position #2
Z X
215
In the same manner, define Position #3 and Position #4 using the model faces as
shown.
Position #3 Position #4
Shift (0,100,-35) Shift (0,100,0)
Rotation (180,0,0) Rotation (90,0,0)
Confirm the CoordSys Manager dialog box with .
216
4. Indexial 4-Axis Milling
217
Click the Insert command in the SOLIDWORKS menu and choose the Existing
Part/Assembly option from the Component sub-menu.
218
4. Indexial 4-Axis Milling
In SolidCAM Manager, right-click the Fixtures header and choose the Define Fixture
command from the menu.
The Model dialog box is displayed.
This dialog box enables you to define the fixture by selecting solid bodies of the
CAM-Part assembly components.
Click on the clamping device model as shown.
219
The Machine setup dialog box is displayed.
Until this moment, no
fixture has been chosen
for operation, therefore
the Fixture cell in the table
contains the None field.
Click this field and choose
the clamping fixture option
for the fixture that you have
defined earlier.
In the Z cell, type in 35 to
raise the model 35 mm above
the machine table. Confirm the dialog box by clicking OK.
220
4. Indexial 4-Axis Milling
Choose the Coordinate System Position #1 in the Geometry page of the Pocket
Operation dialog box.
221
Define the Geometry as shown.
Choose the Tool #1 (Ø10 End mill) for
the operation.
Define the Upper level for the
operation on the top face of the
pad (used in the previous operation
for the Pocket depth definition).
Set the Wall offset and the Floor offset values to 0.2 to leave allowance for the
further finishing.
Use the Helical Ramping strategy. Set the Radius value to 5.
222
4. Indexial 4-Axis Milling
Set the Delta value for the Pocket Depth to -1 to perform the through pocket
machining.
Set the Wall offset value to 0.2 to leave allowance for the further finishing.
Use the Helical Ramping strategy. Set the Radius value to 5.
223
Use the geometry defined in Step #9.
Choose the Tool #1 (Ø10 End mill) for the operation.
Use the same milling levels that were defined in Step #9.
Choose the Arc strategy for Lead in and select the Same as Lead in check box under
Lead out.
224
4. Indexial 4-Axis Milling
225
17. Define a Profile operation
In the same manner as explained in Step
#13, define a Profile operation to perform
the finish machining of the highlighted
faces. Use the Coordinate System Position
#3 for the operation.
Define a new End mill tool of Ø6 for the operation. Choose the appropriate tool
holder.
226
4. Indexial 4-Axis Milling
227
• Each step down
228
4. Indexial 4-Axis Milling
Chamfer mill
This tool is used for chamfering. A tool of this type is defined with
the parameters shown in the image.
Arbor Diameter
Total
Length Outside
Shoulder
Holder
Length
Length Cutting
Length
Angle
Diameter
229
Set the Cutting diameter value to 2.
In the Link section of the Profile Operation dialog box, choose the Arc strategy for
Lead in and select the Same as Lead in check box under Lead out.
In the same manner, define a new Profile operation to machine another chamfer of
0.5 mm using Coordinate System Position #3.
230
4. Indexial 4-Axis Milling
Define the CAM-Part and operations for machining of the mounting part shown below on the
4-axis vertical milling CNC-machine.
231
Using the Flip options in the CoordSys dialog box, rotate the
Coordinate System so that the X-axis is
collinear with the revolution axis and the
Z-axis is directed upwards as shown.
Z
Define an additional Machine Coordinate
System #2 to machine the back faces of
the mounting part. Y
X
Define the Stock and the Target models using the configurations of the original
SOLIDWORKS model.
2. Face milling
Define a Face Milling operation with the Hatch strategy
to machine the shown face.
Use the Machine Coordinate System #1 (Position #1)
for the machining.
3. Holes machining
Define three Drilling operations to perform center
drilling, drilling and threading of the M6 holes.
232
4. Indexial 4-Axis Milling
Now you have to define a circular pattern of the operations around the revolution
axis (4th axis) of the CAM-Part in order to machine all the sides.
In SolidCAM Manager, select all the defined
operations holding the Shift or Ctrl keys. Right-
click one of the selected operations and choose the
Transform option from the menu.
Operation transformations
This section offers you the choice of whether the original operation
will be transformed or its copy will be added for transformation
and, in the latter case, enables you to define the placing of the new
operation in the SolidCAM Manager tree.
The following options are available:
• Edit operation transformations
233
• New operation (add at current position in operations tree)
234
4. Indexial 4-Axis Milling
235
6. Remove the clamping tail
Define a Face Milling operation with the Hatch
strategy using the Machine Coordinate System
#2 to remove the tail that was necessary for the
part clamping at the 4th axis operations.
236
Indexial 5-Axis
Milling 5
SolidCAM enables you to perform indexial 5-axis milling using either vertical or horizontal
5-axis CNC-machines.
The 4th and 5th axis rotation is used for
positioning of a part. When the part is
positioned to the necessary orientation, the 4th
and the 5th axes are locked and machining is
performed with 3-axis movements.
For each clamping, SolidCAM enables you to
define the Machine Coordinate System.
Machine
Coordinate
System
238
5. Indexial 5-Axis Milling
SolidCAM enables you to perform indexial 5-axis milling using either vertical or horizontal
5-axis CNC-machines.
Z
Y
Z Y
Positions
Z Z
Y Y
X X
The 4th and 5th axis rotation is used for positioning of a part. When the part is positioned to
the necessary orientation, the 4th and the 5th axes are locked and machining is performed with
3-axis movements.
For each clamping, SolidCAM enables you to define the Machine Coordinate System.
239
For each clamping (Machine Coordinate System), SolidCAM enables you to define a number of
related positions around the Machine CoordSys. Take care of the machine limitations (angles or
undercuts).
Shift X
Machine
Coordinate Z Y
System
Shift Z
X'
Position
Y' Z'
Shift Y
Machine X'
Z Y
Coordinate Position
System Y' Z'
X
Rotation:
X= 0
Y= -90
Z= 180
240
5. Indexial 5-Axis Milling
For each position, SolidCAM automatically determines the Shift and Rotation parameters relative
to the Machine Coordinate System.
Machine Coordinate Systems and their positions are used for the geometry definition. Before
the geometry definition you have to choose the Coordinate System position. The geometry has
to be located in the plane parallel to the XY-plane of the chosen CoordSys.
241
Exercise #14: Clamp Machining
Define the CAM-Part and operations for the machining of the clamp shown below on the 5-axis
vertical milling CNC-machine.
242
5. Indexial 5-Axis Milling
Machine Coordinate
System #1
Position #1
Machine Coordinate
System #1
Position #2
Machine Coordinate
System #1
Position #3
243
Machine Coordinate
System #1
Position #4
Machine Coordinate
System #1
Position #5
Machine Coordinate
System #2
Position #1
Define the Stock model using the Stock configuration of the CAM-Part assembly.
Define the Target model using the Machining configuration of the CAM-Part
assembly.
244
5. Indexial 5-Axis Milling
5. Openings machining
Define a Profile operation to machine two openings
located on the front inclined face of the clamp. Use
the Machine Coordinate System #1 (Position #4) for
the operation.
6. Slot machining
Define a number of operations to machine the slot
faces located on the top inclined face of the clamp.
Use the Machine Coordinate System #1 (Position #2)
for the operation.
7. Hole machining
Define a number of operations to machine the
inclined counterbore hole located on the top inclined
face of the clamp. Use the Machine Coordinate
System #1 (Position #5) for the operation.
245
8. Bottom face machining
Define a Face Milling operation with the Hatch
strategy to machine the bottom inclined face of
the clamp. Use the Machine Coordinate System #2
(Position #1) for the operation.
246
ToolBox 6
ToolBox sub-operations are a set of 2.5D Milling operations, each intended for a specific
machining case. Some operations cover different strategies of slots machining. Each sub-
operation provides you with a specific machining strategy optimal for a particular machining
case.
These operations are combined in a single dialog box as sub-operations.
SolidCAM offers you the following types of ToolBox Cycles:
ToolBox Cycles
Flattened Surface
Spiral Open Slot Temporary Bridges
on Cylinder
Roll into Open Slot One Side Open Slot Wood Cutting
248
6. Toolbox
Simple Slot
This strategy enables you to perform one-pass machining of the
slots with the width equal to or smaller than double diameter of
the tool.
249
Closed Slot
This strategy enables you perform machining of a closed slot with
the width equal to the tool diameter. The machining is performed in
the zigzag manner; the last cut is horizontal to clean the slot floor.
Spine Slot
This strategy enables you to perform machining of a slot opened
from one side. SolidCAM automatically determines the spine of the
slot and performs the machining according to the spine’s shape. In
this sub-operation, the tool approaches the material along the spine
and then machines the walls of the slot.
Temporary Bridges
This strategy enables you to machine the profile of a pocket while
preserving the rest of the material fixed to the wall using small thin
bridges. Inner material will be hammered for shorter machining
time.
Simple Corner
This strategy enables you to perform machining of an open corner
area in a number of equidistant cutting passes..
Broaching
This strategy enables you to perform broaching of holes.
250
6. Toolbox
Ruled
This strategy enables you to perform the machining of an analytical
ruled surface defined by two open contours. The cutting passes are
evenly distributed between the defined contours.
O-Ring
This strategy enables you to machine O-Ring slots.
Rib Cut
This strategy enables you to machine a rib upper surface in a single
pass shifted from the center line by a specified value. This is a safe
method of cutting the upper face of a thin wall.
251
Flattened Surface on Corner
This strategy enables you to machine an angled plane using a defined
working area in order to prevent air cuts.
Simple Boss
This strategy enables you to perform machining of a boss located on
a model face. The machining is performed in a number of equidistant
cutting passes parallel to the boss geometry. The passes are cut with
the outer contour of the initial face.
Spiral Pocket
This strategy enables you to perform machining of the closed pocket
areas using spiral techniques. With this strategy, the tool penetrates into
the material in the automatically calculated point inside the pocket with
a helix. Then the tool performs the spiral cutting pass morphing from
the penetration point to the closed area walls.
Wood Cutting
This strategy uses a special tool called “saw” to cut off a block of wood
in a single pass. The First Step down parameter defines the depth of
cutting.
Angled Cylinder
In this cycle, the cylinder top is cut to create an angled surface. The
cutting is performed by parallel cuts with a defined Step over.
252
6. Toolbox
253
The ToolBox cycles operation dialog box is displayed.
Make sure the default Spiral open slot strategy is chosen in the top left corner under
Technology.
In the Technology page, under Offsets, set Wall offset to 0.5. Under Extension, set
% of tool diameter to 80. Under
Finish, select the Wall finish
option.
Click the Save icon.
254
6. Toolbox
255
Use the same tool as in the previous operation. Click the Save icon.
256
6. Toolbox
In the Closed Slot cycle, the tool diameter should be equal to the slot
width.
257
9. Spine Slot machining
Define a new ToolBox Cycles operation.
Under Technology, select the Spine Slot strategy.
Define a new geometry, selecting the open chain as shown.
Define a new End mill of Ø10 for this operation and edit the following parameters:
• Set the Shoulder length to 60
• Set the Cutting length to 60
258
6. Toolbox
12. Broaching
Define a new ToolBox Cycles operation.
Under Technology, select the Broaching strategy.
Define a new geometry, selecting a linear chain as shown.
259
Broaching Tool
The tool of this type can only be used within the Broaching sub-
operation. It is not available for defining or choosing in any other
operation.
Arbor
Diameter
Total Cutting
Length Length Outside
Holder
Shoulder Length
Length
Width Depth
Corner Radius
Add a new Broaching tool and set its Width and Depth to 6.
In the Technology page, set the Tool side to Left.
260
6. Toolbox
In the Technology page, set the Approach distance value to 1.25. Under Extension,
set % of tool diameter to 60.
261
16. Ruled Surface machining
Define a new ToolBox Cycles operation.
Under Technology, select the Ruled strategy.
Define a new geometry, selecting a pair of open chains on the slot edges.
262
6. Toolbox
263
20. Surface flattening on corner
Define a new ToolBox Cycles operation.
Under Technology, select the Flattened surface on corner strategy.
For this operation, define a new Coordinate
System position with the origin located on the
flattened surface plane.
Define a new geometry, selecting a straight line
chain.
In the Working area section, click the Define
button to assign a triangle working area to the
selected line.
264
6. Toolbox
265
23. Wood cutting
Define a new ToolBox Cycles operation.
Under Technology, select the Wood cutting strategy.
Add a new Saw tool of Ø40. Set the Shank width to 20.
Saw Tool
This tool type can only be used with the Wood cutting sub-operation.
It is not available for defining or choosing in any other operation.
266
6. Toolbox
A tool of this type is defined with the parameters shown in the image.
Shank Width
Outside
Holder
Diameter
Total Internal
Length Diameter
Blade Saw
Thickness Thickness
267
25. Thin Wall Machining
Define a new ToolBox Cycles operation and select the Thin Wall Machining strategy.
Define a new geometry, selecting two edges as shown.
268
6. Toolbox
269
270
Automatic Feature
Recognition 7
This chapter covers the following types of 2.5D Milling operations performed using the
Automatic Feature Recognition module (AFRM) functionality:
Pocket Recognition Operation
This operation enables you to recognize pocket features on a solid model and perform machining
of these features.
272
7. Automatic Feature Recognition
A Geometry for Pocket, Chamfer, and Drill Recognition operations is determined automatically
by SolidCAM AFRM functionality.
273
Exercise #16: Pocket Recognition
Alternatively, you can choose the Pocket Recognition icon from the SolidCAM
AFRM ribbon. The Pocket Recognition Operation dialog box is displayed.
274
7. Automatic Feature Recognition
Through Pocket
When this check box is selected with the Selection Mode set to Solid
Body, the recognition of through pocket features is also performed.
Through Pockets
Only the through pocket features where the upper loop is identical to
the lower loop are recognized. The Upper loop
through pocket features that cannot be
machined with the current CoordSys
position cannot be selected.
In the Circular Pocket diameter filter
section, make sure that the Apply filter
check box is selected. Lower loop
275
Circular Pocket diameter filter
When the Apply filter check box is selected with the Selection mode
set to Solid Body, circular pocket features can be selected according to
their diameter. All circular pocket features with the diameter greater
than the specified Min. Diameter value will be selected. Using this
option, you can avoid machining of drill features that are supposed
to be machined in other operations (Drilling, Drill recognition, etc.).
The Min. Diameter parameter defines the minimum diameter of the
pocket features. You can enter the value in the edit box or pick a cylindrical
surface or a circular edge on the solid model when the cursor is placed in the
Min. Diameter edit box.
The Min. Face area parameter enables you to set a value to avoid
picking up very small areas or faces that cannot be machined.
When the Circular Pocket check box is not selected, all recognized
circular pocket areas suitable for the current Coordinate System are
selected.
Selection Mode
This section enables you to set the mode of the geometry selection.
The following selection modes are available:
• Solid Body
276
7. Automatic Feature Recognition
Selected faces
Undercut face
(selection rejected)
• Face
This mode enables you to pick single planar faces. When a face is
picked, SolidCAM checks the parallel relation between the surface
normal vector of the picked face and the positive direction of the
Z-axis of the current CoordSys. If they are not parallel, the face
is not selected. The undercut faces that cannot be machined with
the current CoordSys position are also not selected. The selection
is working in the toggling mode: the first click on a face selects it,
the next click on the selected face removes the selection.
• Through Pocket Chain
277
Under Selection mode, use the default Solid Body option.
Click on the solid model. SolidCAM generates the list of elements that suit your
filter settings.
Click the Solid1 element in the list. All the recognized model
features that take part in this geometry are highlighted. The
geometry includes all the planar faces, through pockets of
slots, and circular through pockets of column holes. Each
model element is accompanied by its Z-level value enclosed
in parentheses.
278
7. Automatic Feature Recognition
279
7. Define the Ramping strategy
In the Link page, choose the Helical ramping strategy and set the Radius to 5.
The chosen ramping strategy affects the close pocket areas where the horizontal
approach from outside (defined in the previous step) is impossible.
Click .
280
7. Automatic Feature Recognition
The following steps have to be implemented in order to reach the final CAM-Part:
3. Pocket roughing
Define a Pocket Recognition operation
to remove the bulk of material and
perform the rough machining of
the part inner surfaces. Use the End
mill tool of Ø20 used in the previous
operation.
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4. Pocket rest material machining
Define a Pocket Recognition operation
to perform the rest material machining
of the part inner surfaces. Use an End
mill tool of Ø10.
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7. Automatic Feature Recognition
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3. Define the Geometry
In the Geometry page, click .
SolidCAM parses the solid model and recognizes all of
its hole features.
The HR Drill Geometry Selection dialog box is displayed. This
dialog box enables you to specify the holes to be included in
the operation geometry.
In this operation, you will perform the center drilling of all
the holes that can be machined using the defined CoordSys
position, except for the column holes that were machined in
the previous operation as through pocket features.
In the Hole Type section, make sure that both the Through
and Blind check boxes are selected. In this operation, both
through and blind holes will be drilled.
The HR Drill Geometry Selection dialog box enables you to
filter the hole features to be machined by diameter, upper
level and height.
Select the Hole Diameter check box.
When this section is activated, the hole features are filtered according
to the diameter of the hole. With this filter, only the hole features with
the Hole Diameter value within the specified range are recognized.
The From and To values enable you to define the Diameter range by
entering the values or by picking on the solid model.
When the cursor is placed in the From/To edit box, you can specify the
diameter value by picking a specific cylindrical surface or a circular
edge on the solid model.
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7. Automatic Feature Recognition
Define the upper limit for the diameter range. Place the cursor in the To edit box and
pick the edge of the column hole as shown. The
diameter of the hole (42 mm) is displayed in the edit
box.
In this operation, the holes will be machined irrespective of their upper levels. Make
sure that the Hole Upper level check box is not selected.
When this section is activated, the hole features are filtered according
to the Upper level. With this filter, only the hole features with the
Upper level value within the specified range are recognized.
The From and To values enable you to define the Upper level range
by entering the values or by picking on the solid model. When the
cursor is placed in the From/To edit box, you can specify the Upper
level value by picking on the solid model. When a model point is
picked, the Z-value of the picked position is calculated and inserted
into the corresponding edit box replacing the previous value. The
edit box changes the background color to indicate the associativity
field (by default, pink).
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When you remove the automatically determined value, the edit box
background turns white again.
In this operation, the holes of all heights will be machined. Make sure that the Hole
height check box is not selected.
When this section is activated, the hole features are filtered according
to the Hole height. With this filter, only the hole features with the
Hole height value within the specified range are recognized.
The From and To values enable you to define the Hole height range
by entering the values or by picking on the solid model. When the
cursor is placed in the From/To edit box, you can specify the Hole
height value by picking on the solid model. When a model point is
picked, the Z-value of the picked position is calculated and inserted
into the corresponding edit box replacing the previous value. The
edit box changes the background color to indicate the associativity
field (by default, pink). When you remove the automatically
determined value, the edit box background turns white again.
Click the Find Holes button. The hole features that match
the specified filter criteria are determined. These features are
listed in the Holes Tree section.
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7. Automatic Feature Recognition
Click the Preview button. The hole features are highlighted on the model.
Holes Tree
In this list, the recognized hole features are classified by Shapes and
Groups. A Shape contains all the hole features with the same
topology; within a Shape, the Groups include all the hole features
with the same parameter values (Upper Level, Height and Diameter).
For each Group, the Upper level (u) and Height (h) are displayed in
parentheses. When you select a Shape or a Group item in the list, the
hole features that belong to this Shape or Group are highlighted on
the model.
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Notice the list of drill instances displayed in the Holes Tree section.
Holes Tree
This section displays the list of all drill instances chosen for the
geometry. All the drill instances in the list are structured into Groups
with the same Upper Level, Drill Depth, Delta Depth and Depth Type.
For each Group in the list, the drill instances data are displayed in
parentheses. Each drill instance in the list is accompanied by the
X- and Y-coordinates of the drilling position. Selecting the check
boxes next to each element in the list enables you to include the hole
features, Shapes or Groups into the geometry.
Do not confuse the Group classification in this dialog
box with that taking place at the stage of geometry
definition.
By default, the Depth Edit dialog box displays the parameter values recognized from
the solid model. Now you need to define the Upper Level, Drill/Chamfer Depth and
Depth Type parameters for each group of drill instances separately.
Select the Group1 item in the Holes Tree section. The drill instances that belong to
this group are highlighted on the model.
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7. Automatic Feature Recognition
Depth Type
289
The following options are available:
• Cutter Tip
The drill reaches the defined drilling depth with the full diameter.
• Auto Chamfer/Spot drill
The drill reaches the defined drilling depth with the drill cone
diameter specified by the Diameter Value parameter.
The Apply button enables you to apply the defined Depth Type to
the selected list item (a group or a hole). When a new Depth Type
is applied, SolidCAM checks the Holes Tree items and reorganizes
them into groups according to the changed parameters. the program
checks all groups to find a group with identical Upper Level, Drill
Depth, Delta Depth and Depth Type parameters. If such group is
found, the program adds the updated drill to this group. In case of
absence of a suitable group, a new group is created; the updated drill
instance is added to this group.
Choose the Auto Chamfer option for Depth Type. The Drill depth section name
changes to Chamfer depth. This type should be applied to all hole features in the
operation. Select the All check box and click the Apply button.
Notice that if you do not click the Apply button after editing values, the
change does not take effect.
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7. Automatic Feature Recognition
The edit box has pink background, which means that the parameter
is defined associatively to the solid model. When the edit box value
is typed in, it is not associative to the model; in this case the edit box
has white background.
The Apply button enables you to apply the defined Drill Depth value
to the selected list item (a group or a hole). When a new Drill Depth
value is applied, SolidCAM checks the Holes Tree items and
reorganizes them into groups according to the changed parameters.
the program checks all groups to find a group with identical Upper
Level, Drill Depth, Delta Depth and Depth Type parameters. If such
group is found, the program adds the updated drill to this group. In
case of absence of a suitable group, a new group is created; the
updated drill instance is added to this group.
Set the Chamfer depth value to 0.2, select the All check box
and click the Apply button.
Apply the changes and confirm the Depth Edit dialog box
with .
291
The Advanced Sorting dialog box is displayed. This dialog box enables you to define
the parameters of sorting of drill positions for machining of linear and circular drill
patterns.
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7. Automatic Feature Recognition
Choose the option in the Linear tab of the Advanced Sorting dialog box, and
set the Tolerance value to 5.
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In the Advanced Sorting dialog box, click the OK button to confirm the definition
of sorting parameters.
Click the Show Sorted
button to preview the
sorted drill positions on
the solid model.
Close the Show
Geometry dialog box
with .
Click .
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7. Automatic Feature Recognition
Click the Find Holes button. The holes of the specified diameter are highlighted on
the model.
295
Add a new Ø6.8 Drill tool.
In the Linear tab of the Advanced Sorting dialog box, choose the option.
When this option is chosen, SolidCAM determines the position with the
minimal X- and Y-coordinates and
accepts it as the start position of the
drill sequence. From this position, the
program continues the machining of
the drills with the same X-coordinate;
the machining is performed in the
direction of increasing Y-coordinates.
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7. Automatic Feature Recognition
When the last position of the current X-coordinate is machined, the
program passes to the next X-coordinate (in the increasing order) and
continues the machining of the next column from the position with the
maximal Y-coordinate to the position with the minimal Y-coordinate
(decreasing order), and so on. In such manner, the machining of two
successive columns is performed in the opposite order: each odd column is
machined in the direction of increasing Y-coordinates, each even column is
machined in the direction of decreasing Y-coordinates.
The columns are ordered in the direction of increasing X-coordinates.
Click the Show Sorted button to preview the sorted drill positions on the solid model.
Under Drill cycle, click the Drill cycle type button and choose the Peck type from the list.
Click the Data button to define the pecking parameters.
In the displayed Drill Options dialog box, set the Step down
value to 2 and confirm the dialog box with the OK button.
Save and calculate the operation.
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10. Machine the Ø8 holes
Add a new Drill Recognition operation to perform drilling of the Ø8 holes.
In the HR Drill Geometry Selection dialog box, activate the Hole Diameter section.
Define the range for the Hole Diameter filter as explained in the previous step. The
values of 8 mm are displayed in the Hole Diameter section.
Add a new Drill tool. The diameter of the drilling tool must be smaller than the
diameter of the holes, because these holes will be reamed at the next stage.
You can define the diameter of the tool by clicking on the entity to be
machined with this tool
directly on the solid
model. Place the cursor
in the Diameter edit
box in the Topology
page of the Part Tool
Table and pick the edge
of the hole as shown.
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7. Automatic Feature Recognition
In the Linear tab of the Advanced Sorting dialog box, choose the option,
set the Tolerance value to 2 and click the Show sorted
button.
Under Drill cycle, choose the Peck cycle type and set
the Step down value to 2.
Save and calculate the operation.
In the HR Drill Geometry Selection dialog box, define the range for the Hole Diameter
filter as explained in the previous steps. The values of 4.2 mm will be displayed in
the Hole Diameter section.
Add a new Ø4.2 Drill tool.
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In the Technology page, choose the Advanced option under Sorting and click the
button.
In the Linear tab of the Advanced Sorting dialog box, choose the option and
click the Show Sorted button.
Under Drill cycle, choose the Peck cycle type and set the Step down value to 2.
Save and calculate the operation.
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7. Automatic Feature Recognition
301
Click the Show Sorted button to preview the sorted drill positions on the solid
model.
302
7. Automatic Feature Recognition
Reamer
Total
Outside
Length
Holder
Length
Cutting
Length
303
The Drill depth value (12) is displayed. Click the Apply button.
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7. Automatic Feature Recognition
Default Stock
The following steps have to be implemented in order to reach the final CAM-Part:
305
17. Drilling
Define a Drill Recognition
operation to perform drilling
of the Ø1.2 holes. Use a Drill
tool of Ø1.2.
18. Drilling
Define a Drill Recognition
operation to perform drilling
of the Ø1.8 holes. Use a Drill
tool of Ø1.8.
19. Drilling
Define a Drill Recognition
operation to perform drilling
of the Ø2.2 holes. Use a Drill
tool of Ø2.2.
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7. Automatic Feature Recognition
This exercise illustrates the SolidCAM functionality of automatic chamfer recognition and
machining.
This exercise reinforces the following skills:
• Automatic chamfer recognition and
machining
The following steps have to be implemented in
order to reach the final CAM-Part:
307
First, you need to set the chamfer recognition filters and then the mode of geometry
selection.
In the Circular Pocket diameter filter section, make sure
that the Apply filter check box is selected.
When this check box is selected with the Selection mode set to Solid
Body, circular pocket features can be selected according to their
diameter. All circular pocket features with the diameter greater than
the specified Min. Diameter value will be selected for chamfering.
The Min. Diameter parameter defines the minimum diameter of the
pocket features. You can enter the value in the edit box or pick a cylindrical
surface or a circular edge on the solid model when the cursor is placed in the
Min. Diameter edit box.
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7. Automatic Feature Recognition
Set the Min. Diameter value to 20. All of the holes with the diameter smaller than the
specified value will not be chamfered.
Define the mode of geometry selection. Under Selection mode, use the default
Solid Body option.
Click on the solid model. SolidCAM generates the list of elements that suit your
filter settings.
Click the Solid1 element in the list. All the recognized model
features that take part in this geometry are highlighted. The
geometry includes all the planar faces, through pockets of
slots, and circular through pockets of column holes. Each
model element is accompanied by its Z-level value enclosed
in parentheses.
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5. Define the machining levels
Define the Chamfer depth by setting the value to 0.5.
Safety offset
Click .
Congratulations!
You have successfully finished the 2.5D Milling part of the SolidCAM 2020 Milling Training Course.
310
SolidCAM Training Course
2.5D Milling
the MILLTURN Edge
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